Lets Get Practical

Ross Mackay, Contributing Editor

Multiple Pump Operation

ne of the challenges that pump users face quite frequently comes into play when more than one pump is required to operate at the same time on the same system. With such multiple pump systems, there are two arrangements where the operating characteristics of the different pumps can be considered to provide a single combined performance curve. The first arrangement is a series operation, where one pump discharges directly into the suction of the second pump, with both pumps delivering the same flow rate, but sharing in the development of the combined pressure. The second arrangement is parallel operation, where each of two (or more) pumps takes its suction from a common header and discharges into another common header, thus sharing the flow while operating at the same head.

The ultimate example of series operation is the multistage pump, where the first impeller pumps into the second, then into the third, etc. This results in a high-pressure pump with all the impellers operating at the same capacity. Lets Get Practical. In some pumping arrangements, we can have multiple pumps that operate on two systems that are closely combinedbut theyre not in a true series operation and cannot be considered as such. One such example would be when one pump is supplying the flow and pressure for one system, while the second pump is bleeding off the first system to deliver a lesser flow to another system. While one pump is indeed discharging into the suction of the second pump, it is doing so at a different flow rate. Consequently, they cannot be treated as though they were operating in series.

Parallel Operation
In the more common parallel operation, banks of pumps are combined in order to handle a high fluctuation of flows in a common system. This arrangement is widely used in the water treatment business, where the potable water being supplied to a subdivision from the treatment plant will experience huge fluctuations in demand from one time of day to another. The use of multiple pumps on the same system allows the pumps to be switched on and off as required to meet the varying demand. In such arrangements, all the pumps take their suction from a common source and discharge into

Series Operation
This arrangement is often used where a larger pump cannot operate with the NPSH thats being made available from the system. A smaller pump is, therefore, installed upstream of the larger one to boost the suction pressure to the larger pump. It should be noted that in the series operation, the only essential similarity between the two pumps is that they must both be able to operate at the same flow rate. The pumps can deliver totally different levels of head, as long as they operate at the same capacity. (See Figure 1.)

Figure 1. Series pump curves

Figure 2. Parallel pump curves

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JULY 2004

a common header. Each pump will operate at the same head, but share the flow rate with the other pumps. (See Figure 2.) Because of the slope of the system curve, the pumps in this arrangement will each operate at a lower flow rate when operating together, than they would if they operate alone on the same system. This is particularly relevant on multi-pump arrangements, and it requires careful selection to ensure the most efficient and stable operation.

Too Many Pumps in Parallel

Lets Continue Being Practical. Multi-pump systems are also susceptible to the danger of having too many pumps in parallel on the same systemparticularly if they exceed the number of pumps for which the system was originally designed. As each pump runs at a lower flow rate when operating together, than they would if they were operating alone on the same system, a steady increase in numbers of pumps will reduce the flow rate through each pump. As shown in Figure 3, this could result in the final pump adding only a fraction of its capability to the system output.

Figure 4. Variable speed pump curves

However, if the system curve moves to a steeper slope, where it cuts the combined curve at a head that is higher than the shut-off head of the slower pump, then that slower pump will not be contributing any flow to the system. At that point, it becomes essential for the slower pump to have a non-return check valve on its discharge. Otherwise, the faster pump will be reversing the flow backwards from the discharge header into the discharge nozzle of the slower pump. This could impose a significant reverse torque on the impeller of the slower pump with severe results.

Piping Arrangements
Multiple pump arrangements present a great temptation for system designers to ignore the rules of pipingwith serious results! Poor piping arrangements are almost the norm in packaged systems where multiple pumps are used. It is imperative that proper piping practices be maintained for each pump in a multiple pump arrangement. These include:
Figure 3. Multiple parallel pump curves

Variable Speed Difficulties

Another practical problem with two pumps in parallel can occur when one of the pumps has a variable speed driver. This arrangement is also frequently used to fluctuate the total output of both pumps. Under the condition when one pump is slowed to a speed lower than the other, the combination of head and capacity of both pumps will involve the slower pump only after the shut-off head of that pump is reached. At that point only, the capacity from the slower pump will be added to the capacity of the faster pump to provide a combined output. A similar situation can occur if two pump styles with different performance curves are installed and operated in a parallel arrangement. (See Figure 4.)
PUMPS & SYSTEMS

no elbows on the suction nozzle of the pump; zero pipe strain on the pump; a straight run of 5 to 10 times the pipe diameter to the suction nozzle; both sets of piping to be, at least, one size larger than the pump nozzle; use of an eccentric reducer on the suction side, with the flat side up.

So, Stay Practical. With multiple pump arrangements, it is essential that both the hydraulic and mechanical aspects of system design be considered in order to ensure a high degree of reliability. P&S
Ross Mackay specializes in helping companies increase their pump reliability and reduce operating and maintenance costs through consulting and education. He can be reached at 1-800-465-6260, or through his web site at www.rossmackay.com 11

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JULY 2004